Stark S-3000 Guide

STARK®S-3000 & S-3000L
Installation, Operation & Maintenance Instructions (IOM)
GENERAL NOTICE
The information provided in this document is very important and needs to be shared with anyone
involved in the installation, operation, and maintenance of the closure(s).
SAFETY NOTICE
Do not open the closure unless you are sure there is no pressure within the closure. All operators
should use the appropriate Personal Protective Equipment (PPE) and operating tools.
WELDING NOTICE
During welding, warpage can occur due to the heat generated. Please read sections 2.2 & 2.3 for
recommendations to reduce warpage caused by welding. Excessive warpage will damage the
product.
STARK®appreciates the support of all supervisors.
Should you have any questions or concerns not addressed in this IOM,
please contact us directly for assistance.
STARK® SOLUTIONS
10650 FM 1484 Rd.
Conroe, TX 77303
Phone [phone]
Email: [e-mail]
www.starksolutions.com
STARK® SOLUTIONS IS ASME “U” & “R” & ISO 9001-2015 CERTIFIED

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Table of Contents
Section 1: INTRODUCTION Page 03
Section 2: INSTALLATION Page 04
Section 2.1: General Installation Notes Page 04
Section 2.2: Installation of Closure Hub in the Field (Manual Welding) Page 04
Section 2.3: Installation of Closure Hub in the Fabrication Shops (Automatic Welding) Page 05
Section 3: OPERATION Page 06
Section 3.1: Opening the Closure (Horizontal) Page 06
Section 3.2: Closing the Closure (Horizontal) Page 07
Section 3.3: Opening & Closing the S-3000/S-3000L Closure (Vertical) Page 09
Section 3.4: Vertical with Wire Rope Winch Page 09
Section 3.5: Vertical with Manual Chain Hoist Page 10
Section 3.6: Vertical with Hydraulic Cylinder w/Pump Page 11
Section 3.7: Vertical with Lifting Eyes Page 12
Section 4: DOOR REMOVAL & INSTALLATION Page 13
Section 4.1: Door Removal Instructions (Horizontal) Page 13
Section 4.2: Door Installation Instructions (Horizontal) Page 14
Section 4.3: Door Removal Instructions (Vertical) Page 14
Section 4.4: Door Installation Instructions (Vertical) Page 15
Section 5: DOOR ADJUSTMENT Page 16
Section 5.1: Horizontal Door Adjustment (Horizontal Hinged) Page 16
Section 5.2: Vertical Door Adjustment (Horizontal Hinged) Page 16
Section 5.3: Horizontal Adjustment (Horizontal Hinged) Page 17
Section 5.4: Door Adjustment (Vertical Hinged) Page 17
Section 6: MAINTENANCE Page 18
Section 6.1: General Maintenance Page 18
Section 6.2: O-rings/Lip seal Maintenance Page 19
Section 6.3: Lock Ring Assembly Maintenance Page 19
Section 6.4: Closure Hub Maintenance Page 21
Section 6.5: Pressure Alert Valve (PAV) Maintenance Page 21
Section 7: REFERENCE DRAWINGS Page 22

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Installation, Operation & Maintenance Instructions for
6” to 84” S-3000 & S-3000L Internal Door Closure
Section 1: INTRODUCTION
The S-3000 Internal Door Closure is manufactured for horizontal
or vertical applications in diameters ranging from 6”to 84”
(DN200 to DN2100), with pressure series ranging from 150 to 2500.
Depending on size and pressure, S-3000 closures come
equipped with a large cross section O-ring or a lip seal. Lip seal
designs are identified as S-3000L. The purpose of this document
is to discuss the installation, operation, and maintenance of the
S-3000/S-3000L Quick Opening Closure.
All closures come equipped with a Pressure Alert Valve (PAV) per
ASME Sec VIII Div. 1 UG-35. The PAV is an integral part of the
opening of the S-3000/S-3000L, as it is attached to a safety
segment of the Lock Ring and must be removed before the Lock
Ring can collapse and the Door can be opened. The PAV design
does not require an O-ring or metal seal ring. In addition, the S-
3000/3000L is a fail-safe design, meaning that even if the Lock
Ring malfunctioned, the Door is still wedged into the Hub.
Opening of the S-3000/S-3000L begins by unscrewing the PAV
stem, then removing the PAV link attached to the safety segment of the locking ring. This allows the
operator to rotate the latch handle, which collapses the Lock Ring sufficiently to disengage from the
Hub. After these steps, the Door and the Lock Ring can be pulled, removing them from the Hub and
opening the Door. Weight bearing components are incorporated to allow for smooth operation
regardless of size or orientation.
Figure 1. S-3000 Horizontal Quick
Opening Closure

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Section 2: INSTALLATION
Section 2.1: General Installation Notes
WARNING: All welding should be performed by qualified welders in accordance with qualified procedures such
as ASME, API, ANSI, etc. These codes require that the welder and the weld procedure be previously qualified.
IMPORTANT: To avoid Hub warpage, complete all nozzle and attachment welds prior to closure installation.
Horizontal closures are designed for installation and operation in the horizontal plane; Door swings in and out
(Figure 2).
Vertical closures are designed for installation and operation in the vertical plane; Door raises and lowers for
opening and closing, respectively (Figure 3).
IMPORTANT: When applying the final paint or coating to the closure, ensure that the Lock Ring and Door ramp is
not painted, as it may hinder the proper operation. A light coating of primer and/or rust preventor is acceptable.
Section 2.2: Installation of Closure in the Field (Manual Welding)
A. Remove the Pressure Alert Valve Stem and Safety Segment from the closure Door.
B. Remove Door, Lock Ring and hinge from the Hub. Refer to Section 4.1 on page 13 for Door removal
instructions for Horizontal closures and Section 4.3 on page 14 for Door removal instructions for Vertical
closures.
C. Fit the Hub to the vessel/pipe. The use of internal or “spider” bracing is recommended, especially on
closures with thinner wall thicknesses.
IMPORTANT: Ensure that the braces are evenly spaced and adhere to the following guidelines depending on
closure size: Up to 30”: 2 braces, Closures 32” to 52”: 3 braces, Closures 54” and larger: 4 braces
D. Weld root and hot passes. The amount of heat should be minimized to avoid possible Hub sealing surface
warpage. A recommended pass sequence is illustrated (Figure 4 on page 05).
Figure 2. Horizontal S-3000
Figure 3. Vertical S-3000

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Section 2.3: Installation of Closure in Fabrication Shops (Automatic Welding)
A. Remove the Pressure Alert Valve Stem and Safety Segment from the closure Door.
B. Remove Door, Lock Ring and hinge from the Hub. Refer to Section 4.1 for Door removal instructions.
C. Fit the Hub to the vessel/pipe. The use of internal or “spider” bracing is recommended, especially on
closures with thinner wall thicknesses.
IMPORTANT: Ensure that the braces are evenly spaced and adhere to the following guidelines depending on
closure size: Up to 30”: 2 braces, Closures 32” to 52”: 3 braces, Closures 54” and larger: 4 braces
D. Weld the root pass. A recommended pass sequence is illustrated (Figure 5).
E. Complete the Hub to vessel/pipe weld using care to minimize heat build up to avoid possible warpage
of the Hub sealing face.
F. Before post weld heat treatment, remove all grease from the Hub. A coating of an anti-splatter product
used for welding will protect against scale build up during the post weld heat treatment.
IMPORTANT: During post weld heat treatment, it is recommended that it be accomplished by localized stress
relieving. If that is not possible, the closure Door and Lock Ring must be removed prior to heat treatment; see
Section 4.1 for Door removal instructions.
G. Close the closure Door (refer to Section 3.2)
Figure 4. Recommended Welding Passes in the field
Figure 5. Recommended Welding Passes in fabrication

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Section 3: OPERATION
All closures are equipped with a Pressure Alert Valve (PAV)
assembly that prevents the Door from being opened while
under internal pressure. The safety segment assembly (Figure
6) consists of the PAV stem, the safety segment, and the PAV
stem Link. The PAV when loosened under pressure, will
generate a whistling noise to alert the operator that the
closure is under pressure. If the pressurizing media is a liquid,
the PAV will leak. The safety segment is connected to the PAV
via the PAV Stem Link and prevents the Lock Ring from being
unlocked while the PAV is installed.
WARNING: Do not attempt to open the closure until all
incoming pressure lines have been closed off and the vessel
or pipe has been relieved of all internal pressure. Opening
under pressure may result in injury to persons and damage to
property.
Section 3.1: Opening the S-3000/S-3000L Closure (Horizontal)
NOTE: Depending on size and pressure, the closure will come equipped with an Activation Bar with a Socket
design, or with a Pivoting Activation Bar design. Both are shown throughout the Horizontal Section of this IOM.
Opening the closure may be performed safely using the following steps:
A. Loosen PAV Stem (if any pressure or residual fluid is
detected, re-tighten the PAV, and do not attempt to
continue opening the closure) and ensure all fluid is
completely drained before continuing. The PAV should
not be used as a vent or drain.
B. Completely remove the PAV stem link and safety
segment from the Door (Figure 6).
C. Rotate the latch approximately 180° counterclockwise
until the Lock Ring is fully collapsed.
D. If the closure is provided with a Pivot Activation Holder
(Figure 7), release the latch on the top hinge plate and
allow the Activation Bar to pivot until it is in the horizontal
position, and pull outward to swing the Door away from
Hub. If the closure does not have the Pivot Activation
Holder, remove the Activation bar from the Activation
Socket (Figure 9 on page 07) and pull outward and swing
the Door away from Hub.
NOTE: Load binders are standard on 24”and larger units with O-rings. If reasonable force will not open the Door,
a load binder may be attached to the activation bar; then extended to assist the Door in opening.
Figure 7. Activation Bar and Pivot
Activation Holder
Figure 6. Latch Assembly & Safety
Segment Assembly

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Section 3.2: Closing the S-3000/S-3000L Closure (Horizontal)
Closing the closure may be performed using the following steps:
A. Wipe off all sealing contact surfaces and ensure all debris and corrosion has been removed. Regrease
the Hub, sealing surface and sealing surface ramp (Figure 22 & 23 on page 18) with a light to medium
lithium grease.
B. Visually inspect O-ring/lip seal for any damage including tears, excessive wear, swell, etc. If breaks or tears
are present, the O-ring/lip seal must be replaced to ensure reliability during operation.
C. Ensure O-ring/lip seal groove is free from corrosion. Re-lubricate if necessary.
D. Release latch and allow the Activation Bar to pivot until it is in the horizontal position, as shown in (Figure
8).
E. Push the Activation Bar inward and carefully swing Door into Hub.
F. Ensure Door is completely seated equally against the Hub prior to compressing the O-ring/lip seal.
Figure 9. Load Binder, Activation Bar & Activation Socket
Figure 8. Load Binder, Activation Bar & Pivot Activation Holder

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G. Using the Activation Bar for leverage, give a fast, quick push to ensure the O-ring/lip seal is compressed
and the Lock Ring is in place. If the Closure is 24” and larger, use the load binder (Figure 8) to assist with
compression.
H. Rotate latch handle to expand locking ring.
IMPORTANT: If Lock Ring does not fit into its internal Hub groove, DO NOT apply force. Verify that the Door is fully
closed, reposition and reattempt.
I. Insert PAV stem into threaded PAV Body in Door while placing the safety segment into the Lock Ring gap.
J. Tighten the PAV Stem by hand, then finish by adding one eighth of a turn using an adjustable wrench. Do
not overtighten.
K. Return the Activation Bar to its vertical position and engage the latch to ensure it stays upright in the Pivot
Activation Holder.
NOTE: If a load binder assist is used, ensure load binder is disengaged as shown in Figure 10 when pressurizing.
Failure to do so will result in damage to the load binder and/or Activation Bar.
WARNING: Do not place hand between the Hub, Door, Lock Ring or hinging while actuating the closure.
Figure 10. Activation Bar Returned to
Upright Position and Load Binder Disengaged
Figure 11. Activation Bar Placed Back into
Activation Holder and Load Binder Disengaged

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Section 3.3: Opening & Closing the S-3000/S-3000L Closure (Vertical)
Vertical closures may come equipped with a Wire Rope Winch (Section 3.4), Chain Hoist (Section 3.5),
Hydraulic Cylinder with pump (Section 3.6), or with Lifting Eyes only (Section 3.7). Follow the below steps, then
see the appropriate section for opening and closing instructions based on the lifting device that was provided.
•Loosen PAV Stem (if any pressure or residual fluid is detected, re-tighten the PAV, and do not attempt to
continue opening the closure). Ensure all fluid is completely drained before continuing. The PAV should
not be used as a vent or drain.
•Completely remove the PAV stem link and safety segment from the Door.
•Rotate the latch handle approximately 180° counterclockwise until the Lock Ring is fully collapsed.
Section 3.4: Wire Rope Winch
A wire rope winch and davit assembly that have a hand operated winch are mounted to a post coming from
the side of the closure.
A. Once the Lock Ring has collapsed, the handle of the winch is turned, winding up the wire, causing the
Door to lift free from the Hub. The winch has a braking system built in, so that when the handle stops
rotating, the load is held in the same position.
B. Once the Door is an inch or more above the Hub, the whole davit assembly (Door included) can be
rotated out of the way for access inside the closure.
C. Wipe off all sealing contact surfaces and ensure all debris and corrosion has been removed. Regrease
the Hub, sealing surface and sealing surface ramp with a light to medium lithium grease.
D. Visually inspect O-ring/lip seal for any damage including tears, excessive wear, swell, etc. If breaks or
tears are present, the O-ring/lip seal must be replaced to ensure reliability during operation.
E. Ensure O-ring/lip seal groove is free from corrosion. Relubricate if necessary.
F. To replace the Door, rotate the davit assembly so that the Door is centered over the closure opening,
and rotate the handle of the winch in the opposite direction, lowering the Door.
IMPORTANT: WHEN LOWERING THE DOOR INTO THE HUB, ENSURE ALL PERSONNEL ARE AT A SAFE DISTANCE TO
AVOID HAZARD OR INJURY!
G. Once the Door is lowered into the Hub, insert the provided handle into the Hub receiver, and push
down, providing leverage to compress the O-ring. If the closure in question has a lip seal, no
compressive leverage will be needed.
H. Rotate latch handle to expand locking ring.
Figure 12. S-3000 with Wire Rope Winch –Door raised and Lowered

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NOTICE: If Lock Ring does not fit into its internal Hub groove, DO NOT apply force. Verify that the Door is fully
closed, reposition and reattempt.
I. Insert PAV stem into threaded PAV Body in Door while placing safety segment into the Lock Ring gap.
J. Tighten the PAV Stem by hand, then finish by adding one eight of a turn using an adjustable wrench. Do
not overtighten.
Section 3.5: Manual Chain Hoist
A load bearing chain and hook assembly hangs below a gearbox with a smaller operation chain hanging off
the side of the gearbox. As the operator pulls on the operation chain, the gearbox translates the motion into
raising or lowering of the load bearing chain assembly.
The gearbox can rotate completely around, allowing the operator to stand in any position around the closure,
but the operation chain is only long enough to reach close to the top of the Hub, so the operator must be at
the height of the top of the closure.
A. Once the Lock Ring has been collapsed, the operator may pull on the operation chain, raising the
Door.
B. When the Door is an inch or more above the Hub, use the activation bar for leverage and move the
whole davit assembly (Door included) so that the operator can access inside the closure.
C. Once the Door is out of the way of the Hub, tighten the T-handle at the davit base to ensure the Door
stays in place (away from the operator).
D. Wipe off all sealing contact surfaces and ensure all debris and corrosion has been removed. Regrease
the Hub, sealing surface and sealing surface ramp with a light to medium lithium grease.
E. Visually inspect O-ring/lip seal for any damage including tears, excessive wear, swell, etc. If breaks or tears
are present, the O-ring/lip seal must be replaced to ensure reliability during operation.
F. Ensure O-ring/lip seal groove is free from corrosion. Relubricate if necessary.
G. To replace the Door, rotate the davit assembly so that the Door is centered over the closure opening,
and pull the operation chain in the opposite direction, lowering the Door.
IMPORTANT: WHEN LOWERING THE DOOR INTO THE HUB, ENSURE ALL PERSONNEL ARE AT A SAFE DISTANCE TO
AVOID HAZARD OR INJURY!
Figure 13. S-3000 with Manual Chain Hoist –Door Raised and Lowered